ME 8451 – MANUFACTURING TECHNOLOGY II

Part-A (06 X 02= 12)

1. Mention the differences between shaper and planer.

In Planer – The work reciprocates while the tool is stationary.
In Shaper – The tool reciprocates while the work is stationary.

2. What is a shell mill?

A shell mill is a large type of face or end mil that mounts on to a arbor, rather than having an integral shank. Typically there is
a hollow or recess in the centre of the shell mill for mounting hardware on to a separate arbor.

3. What is the difference between up milling and down milling?

In up milling, cutter rotates opposite to the direction of feed of the work piece whereas in down milling, the cutter rotates in the
same direction of travel of the workpiece

4. List the types of sawing machines.

Types of sawing machines are (1) Reciprocating saw (2) Circular saw (3) Band saw

5. How are the non-ferrous metals held in magnetic chuck?

Magnetic chucks use magnetic force to hold a workpiece in place while it is being worked on. The magnets work by inducing
polarity into the ferrous work material that connects across its north and south poles. When a workpiece is placed across the
poles of the magnet, the flux flows into it.

6. What are the different operations performed in drilling machine?

Drilling, Counter sinking, Tapping, Reaming
Part-B (02 X 06 = 12)
1. (a) With a neat sketch explain the column and knee type milling machine and name its main parts.

 Small and medium duty machines the table with the job/work travels over the bed [guides] in horizontal [X] and
transverse [Y] directions and the bed with the table and job on it moves vertically [Z] up and down.
 Column is a main supporting frame for the knee,worktable,over arm etc..and houses all the driving mechanisms for
spindle and table feed. Column has guideways on which knee can be moved up or down.
 The knee gives supports the saddle and gives the table vertical movement so that the depth of cut can be adjusted.

[OR]
(b) Explain the features of gear shaping processes.
 Gear shaping uses a cutting tool in the shape of a gear which is reciprocated axially across the gear blank to cut the
teeth while the blank rotates around the shaper tool.
 It is true shape generation process in that the gear shaped tool cuts itself into mesh with the gear blank.
2. (a) Describe the working of a crank and slotted link mechanism.

 Electric motor drives pinion (1)

 Pinion (1) drives the bull gear(14)
 A Radial slide (16) is bolted at the centre of bull gear.
 Radial slide carries a sliding block(12) & a crank pin (11)
 As the bull gear 14 rotates, crank pin 11 rotates.
 So sliding block 12 also rotates on the crank pin circle.
 Simultaneously crankpin will move up & down in the slot of the slotted link 9.
 As the crank pin11 moves, slotted link 9 gets rocking movement.
 This rocking movement is communicated to the ram.
 Thus the rotary motion of the bull gear is converted to reciprocating motion of the ram.

[OR]
 (b) Discuss the principle of operation of a shaper with a neat sketch.

 Shaper drive Mechanism changes rotary motion of power source (Electric motor) to reciprocating motion of Ram.
 Material removal (cutting) of work piece takes place in the forward stroke of ram.
 The return stroke of the ram does no cutting, hence is called Idle stroke.
 The Ram with cutting tool has to move slowly in cutting stroke.
 Since return stroke does no cutting the ram should move faster during return stroke.
 The shaper drive system incorporates quick return mechanism. So that the ram moves faster during return stroke
 Thus minimizing the (idle time) Quick Return time.

Part-C (01 X 06 = 06) Compulsory

1. Explain various milling cutters with neat sketches?

1.End mill:
Types of Milling CuttersIt has both side teeth so it can be very successfully used in drilling operation. The word “end mill” is
generally use to refer flat bottom cutters. The basic difference between drill bit and end mill cutter is that the drill bit can cut
only in axial direction but this cutter can cut in all directions. This cutter has one or more flutes and mostly used in end milling
operation. It is made by High speed steel or harder material.

2. Roughing end mill:

Roughing end mills are also knows as “rippa” cutters. This cutters gives superlative performance in hardest operating
condition. As the name implies it is used to remove large amount of material. This kind of cutter utilizes a wavy tooth from.
These cutters forms very small chips which results rough surface finish.
3. Ball nose cutters:
Ball Nose Cutter is manufactured from qualitative carbide rods. As the name implies this cutter has ball like shape at its nose
which make it able to cut three dimensional shapes very effectively.

4. Slab mill:
This type of cutter is best in quality and can be bought from market with sharp edges. Moreover to this, these milling cutters
are light in weight and can be used safely for longer years. This cutter is used to remove large material from a slab or
machining a large surface. It can be used with both horizontal and vertical or universal milling machine.

5. Hob cutter:
Hob is machine process of gear cutting. A cross section of the cutter tooth will generate the require shape on the work-piece.
Hob cutter is specialist milling machine which is widely use in automobile industry. It is manufactured from prime grade
material which insure high durability and functionality. These are manufactured with quality control process.